Snap-together fencing components

ABSTRACT

A self-locking panel assembly for mounting between a pair of fence posts or deck posts has a first elongate rail having an elongate lower opening, a second elongate rail having an elongate upper opening, and an elongate fence panel having an upper edge and a lower edge. The upper edge of the panel is inserted into the lower opening of the first elongate rail, and the lower edge of the panel is inserted into the upper opening of the second rail. Catches are formed in the first and second rails and/or in the edges of the fence panel such that when the upper and lower edges of the fence panel are inserted into the openings in the rails, the catches hold the fence panel securely in place in the rails.

CROSS-REFERENCE TO RELATED APPLICATION

The benefit of the filing date of U.S. provisional patent applicationSer. No. 61/014,629, filed Dec. 18, 2007, entitled SNAPTOGETHER FENCINGCOMPONENTS, is hereby claimed, and the specification thereof isincorporated herein by this reference.

TECHNICAL FIELD

The present invention relates generally to modular fencing components,and in particular to fencing components that snap together.

BACKGROUND OF THE INVENTION

Outdoor fencing and deck railings have often been made of wood. Inrecent years, plastic/resin has emerged as a material often used tomanufacture fencing and decking products. Plastic/resin fencing and deckrailing products tend to be relatively low cost to manufacture, but canbe more difficult to assemble and install in the field, particularly byend consumers and “do-it-yourselfers” (DIYers). To address this, fencingand deck railings are sometimes factory-assembled into panel assembliesand then sold as completed assemblies ready for installation by theDIYers. While this approach addresses the ease of assembly issue, it canhave other drawbacks. One such drawback is that the assembled panelassemblies can be more costly to ship, as they consume more space inshipping than would the individual parts. This is so because theindividual parts typically can be more densely packed since there is noneed to leave empty spaces between the parts (as there would be in afinished assembly). This same lack of compactness also requires moreshelf space for displaying and retailing the assemblies in a home store.

Accordingly, it can be seen that a need remains in the art for a fencepanel assembly/deck railing assembly that can be shipped and inventoriedas individual components, but which can be assembled and installedquickly and easily by a DIYer or others. It is to the provision of suchthat the present invention is primarily directed.

SUMMARY OF THE INVENTION

Advantageously, the present invention provides a snap-together fencesystem that can be configured largely without the use of the tools.Preferably, the snap-together fence system includes a self-locking panelassembly for mounting between a pair of fence posts or deck posts(typically already driven or sunk into the ground). The self-lockingpanel assembly includes at least one elongate fence panel, such as alattice panel or a privacy panel, and a pair of elongate rails. Thefirst (or upper) rail includes an elongate lower opening, and the second(or lower) rail includes an elongate upper opening. The elongate fencepanel has an upper edge that is adapted to be inserted into the loweropening of the upper elongate rail and a lower edge that is adapted tobe inserted into the upper opening of the second rail. Catches areformed in the upper and lower rails and/or in the edges of the fencepanel such that when the upper and lower edges of the fence panel areinserted into the openings in the rails, the catches hold the fencepanel securely in place in the rails. Preferably, the catches are barbsformed in the edges of the elongate panel. Alternatively, the catchescan be barbs formed in the rails.

Optionally, the self-locking panel assembly includes a third rail and asecond elongate panel. Thus, a pair of panels can be stacked verticallyand mounted between the three rails.

The barbs or catches can take the form of barb-shaped panels or multipleindividual barbs formed along the edge of the panel.

Optionally, the panel assembly can include only one panel, instead of alower panel and an upper panel. Also, the panel(s) can be plain,lattice-like, board-like (having at least the appearance of individualboards), and/or corrugated. Also, individual board-like elements can beprovided, to give the appearance of wooden boards arranged side-by-side,but made from resin/plastic, and utilizing catches to secure theboard-like elements to rails.

Optionally, at least one of the panels is embossed with a wood-graintexture.

Also, optionally the panel assembly includes at least one corrugatedpanel which is shaped and configured to allow multiple ones of thecorrugated panels to be nested during shipping or storage. Preferably,the corrugated panel has barbs or catches formed along at least one edgeand the shape and configuration of the panel is adapted to allowmultiple ones of the panel to be nested, as for stacking in shipment andstorage, without crushing the barbs or catches.

Optionally, at least one of the panels is partially foamed to reduceweight, with the foamed panel having outer layers which are not foamedand sandwiching a foamed core.

The specific techniques and structures employed by the invention toimprove over the drawbacks of the prior art and accomplish theadvantages described herein will become apparent from the followingdetailed description of example embodiments of the invention and theappended drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a modular fence system 10according to a first example embodiment of the present invention.

FIG. 2 is an exploded front perspective view of rail, post and panelportions of the modular fence system of FIG. 1.

FIG. 3 is an exploded side view of rail and panel portions of themodular fence system of FIGS. 1.

FIG. 4 is a perspective view of a portion of the corrugated panel ofFIG. 1.

FIG. 5 is a side sectional view of the portion of the corrugated panelof FIG. 4.

FIG. 6 is a top view of a portion of a corrugated panel similar to thatof FIG. 4 and showing a pair of panel portions connected to one anotherto form a larger corrugated panel.

FIG. 7 is an exploded front perspective view of the connected panels ofFIG. 6.

FIG. 8 is a top view of a portion of corrugated panels of FIG. 4 shownnests together for shipping or storage.

FIG. 9 is a front perspective exploded view of an alternate panelconstruction.

FIG. 10A is an exploded side sectional view of the portion of the paneland rail of FIG. 9.

FIG. 10B is a side sectional view of a portion of the panel and rail ofFIG. 10A.

FIGS. 11A and 11B are side sectional views of panels in optional forms.

DETAILED DESCRIPTION

The present invention may be understood more readily by reference to thefollowing detailed description of the invention taken in connection withthe accompanying drawing figures, which form a part of this disclosure.It is to be understood that this invention is not limited to thespecific devices, methods, conditions or parameters described and/orshown herein, and that the terminology used herein is for the purpose ofdescribing particular embodiments by way of example only and is notintended to be limiting of the claimed invention. Also, as used in thespecification including the appended claims, the singular forms “a,”“an,” and “the” include the plural, and reference to a particularnumerical value includes at least that particular value, unless thecontext clearly dictates otherwise. Ranges may be expressed herein asfrom “about” or “approximately” one particular value and/or to “about”or “approximately” another particular value. When such a range isexpressed, another embodiment includes from the one particular valueand/or to the other particular value. Similarly, when values areexpressed as approximations, by use of the antecedent “about,” it willbe understood that the particular value forms another embodiment.

FIG. 1 is a front view of a modular fence system 10 according to a firstexample embodiment of the present invention. FIG. 2 is an exploded frontperspective view of the modular fence system 10 in FIG. 1. As shown inthese figures, the modular fence system 10 includes a self-locking panelassembly 12 for mounting between a pair of posts 14 and 16 (such asfence posts or deck posts). Preferably, the panel assembly 12 includesan upper elongate panel 18 and a lower elongate panel 20 connectedtogether with a plurality of rails: an upper rail 22, a lower rail 24,and a middle rail 26. As depicted, the upper panel 18 comprises alattice pattern, while the lower panel 20 comprises a corrugated panel.As depicted, the upper panel 18 has dimensions of about 6 feet long×1½feet high×¼ inch thick, while the lower panel 20 has dimensions of about6 feet long×4½ feet high×0.070 inches thick. Thus, in the depictedembodiment, the fence system 10 provides a privacy-type fence with adecorative top. However, those skilled in the art will understand thatthe dimensions can vary in alternative embodiments. For example, boththe upper and lower panels can have dimensions that are approximatelyequal.

Advantageously, the panel assembly can be constructed to have upper andlower panels (as depicted in FIG. 1 and FIG. 2) or simply can have asingle panel. Likewise, while the panel assembly 10 of FIG. 1 shows alower privacy portion and a lattice upper portion, the panel assemblycan be constructed to be all privacy, all lattice, all corrugated, allindividual board-like elements, or various combinations. Likewise, thepanel portions can be single layer constructions or multi-layerconstructions, as will be described in connection with FIGS. 11A, 11B.

In an alternative embodiment, the upper panel can have a picket-likepattern. The pattern can have the appearance of spaced apart pickets orclosely abutting pickets. Still alternatively, the upper panel can beconstructed as a corrugated panel. Similarly, the lower panel can have apattern that has a lattice or picket-like appearance. Those skilled inthe art will understand that the self locking panel assembly 12 caninclude a single panel between a pair of rails or a plurality of panelsstacked vertically and/horizontally between a plurality of rails. Insuch instances, a plurality of horizontally abutting panels can besecured to each rail.

Each rail comprises an elongate opening or channel for receiving aportion of the elongate panel, as best seen in the exploded side view ofthe panel assembly 12 in FIG. 3. As shown, the upper rail 22 includes alower elongate opening 30 for receiving an upper edge of the panel 18.The lower rail 24 includes an upper elongate opening 32 for receiving alower edge of the panel 20. The middle rail 26 includes both an upperelongate opening 34 for receiving a lower edge of the panel 18 and alower elongate opening 36 for receiving an upper edge of the panel 20.Preferably, the elongate openings 30, 32, 34, and 36 each have aconstricted mouth 44 that opens into a wider area 46, as shown withreference to rail 24 in FIG. 3.

Preferably, a plurality of catches or barbs 40 is formed in the edges ofeach fence panel at appropriately spaced apart intervals along orproximate the edges of the panel. The barbs 40 can be die punched fromits respective panel. Alternatively, the barbs 40 can be molded. Thus,when an edge of the fence panel is inserted into the opening of therail, the barbs insert through the constricted mouth of the elongateopening and flare out such that they cannot be pulled back through theconstricted mouth, thereby holding the fence panel securely in place inthe rail.

For example, FIG. 4 depicts a perspective view of a portion of thecorrugated panel 20, and FIG. 5 shows its side view. As shown the barbs40 can be punched from the panel material at approximately ¾″ from thebottom edge and engage the rail 24 to securely hold the panel 20 in therail. Those skilled in the art will understand that in otherembodiments, the catches 40 can have other configurations and placementsand still be within the scope of the present invention.

In the preferred embodiment, the panel 20 is a unitary element thatspans six feet in width. Alternatively, the width of the panel can beachieved by utilizing two narrower panels and linking them together. Forexample, as shown in FIGS. 6 and 7, two more horizontally abuttingcorrugated panels can be linked, with the side edge 50 of the corrugatedpanel 20 rolled or bent to engage a cooperating side edge 52 of anadjacent panel 60, as depicted in FIG. 6. Thus, adjacent corrugatedpanels can be locked together at their sides.

FIG. 7 is a perspective front view of the panels 20 and 60 depicted inFIG. 6. As shown, when the adjacent panels are connected with thecooperating side edges.

Alternatively or additionally, catches or barbs 140 can be formed in therail 122 for holding the panel 120 within the rail, as depicted in FIGS.8, 9, 10A and 10B. Thus, the panel 120 can include a pair of notches 124that cooperates with the barbs 140. Still alternatively or additionally,the front and rear surfaces of the panel 120 can be rough or have atextured surface that the barbs of the rail 122 can engage to securelyhold the panel therein.

Advantageously, the corrugated panels are constructed and configured toallow them to be nested for compact shipping and storage. In thisregard, the “draft” of the angled portions of the corrugations isselected to create interference as the panels nest sufficient to allowclose nesting of the panels, but not so close as to crush the barbs orcatches formed at the edges of the corrugated panels. Preferably, aspace of between about 1/16 and ⅜ inch or so is maintained as ananti-crush zone for the barbs/catches. In this way, the corrugatedpanels can be more economically shipped and stored, without damage tothe panels. When compared to shipping pre-built (pre-assembled) panels,the present invention provides a substantial reduction in shippingspace. Indeed, in a typical prior art pre-assembled panel, perhaps about350 or so panels can be shipped in a standard truck (tractor trailer).By contrast, as many as 1,000 or so of the present panel assemblies canbe shipped (unassembled, but with some parts nested) in the same sizetruck. This allows a sizable reduction in shipping costs. Inasmuch asshipping costs can be on the same order of magnitude as the wholesalecost of the panel assembly itself, this savings in shipping costsstemming from the unique product configuration can be significant.

FIGS. 11A and 11B are side sectional views of panels in optional forms.In FIG. 11A, the panel is shown to have a single layer construction. Inthis form, the panel resin typically is not foamed, so as to maintainappropriate strength and appearance. On the other hand, as shown in FIG.11B, the panel can have a multi-layer construction in which the outerlayers are not foamed, while the inner layer is foamed to reduce weightand cost. It is contemplated that the inner layer can be foamed as muchas 60% or so. This could be manufactured as a multi-layer extrusion. Theparticular foaming agent used can be selected as needed according to thewishes of one skilled in the art. The reduction in resin content byfoaming part of the panel can save substantial money in resin costs andin energy consumed in manufacturing the panel. Indeed, weight savings of25% or so are contemplated in some circumstances.

Preferably, the panels, rails, and posts of the modular fence system 10are constructed of a substantially rigid and durable material such asplastic or resin. In a preferred commercial embodiment, the panels areconstructed of PVC that is white in color, as are the rails and posts,although any weather-resistant resin can be used. Preferably, the resinis UV-stabilized. It is contemplated that PVC may be used to constructother parts of the modular fence system 10 as well. If a resin latticeis included, preferably the lattice is constructed of high densitypolyethylene (HDPE), also white in color. Optionally, the panels, rails,and posts can be embossed to give the appearance of wood grain. Inalternative embodiments, the panels, rails, and posts can be constructedof other resins, aluminum, wood, or a wood-plastic composite material.

To install the modular fence system 10 of the present invention, theuser drives posts into the ground at appropriately spaced locations. Theuser inserts the upper edge of the panel 18 into the lower elongateopening 30 of the upper rail 22 until it snaps (or locks) in place andthe lower edge of the panel 18 into the upper elongate opening 34 of themiddle rail 26 until it snaps (or locks) in place. Similarly, the userinserts the upper edge of the panel 20 into the lower elongate opening36 of the middle rail 26 until it snaps (or locks) in place and thelower edge of the panel 20 into the upper elongate opening 32 of thelower rail 24 until it snaps (or locks) in place. The panel assembly 12(with panels and rails connected together) can be fastened or secured tothe posts with brackets using conventional fasteners or fasteningtechniques.

While the invention has been described with reference to preferred andexample embodiments, it will be understood by those skilled in the artthat a variety of modifications, additions and deletions are within thescope of the invention, as defined by the following claims.

1. A snap-together plastic panel assembly for mounting between two fenceposts or deck posts, the snap-together panel assembly comprising: alower rail with a channel formed therein; an upper rail with a channelformed therein; a middle rail with upper and lower channels formedtherein; a lower panel extending between the lower rail and the middlerail; an upper panel extending between the middle rail and the upperrail; and wherein the rails and the panels are held together bysnap-together connections therebetween.
 2. The snap-together plasticpanel assembly of claim 1 wherein the upper and lower panels are barbed.3. The snap-together plastic panel assembly of claim 2 wherein thebarbed panels each have multiple individual barbs formed therein.
 4. Thesnap-together plastic panel assembly of claim 2 wherein at least one ofthe barbed panels comprises an elongated barb formed along an edge ofthe panel.
 5. The snap-together plastic panel assembly of claim 1wherein at least one of the rails is barbed, having an elongated barbformed along the length of the rail.
 6. The snap-together plastic panelassembly of claim 1 where the lower panel is corrugated.
 7. Thesnap-together plastic panel assembly of claim 1 wherein the upper panelis a lattice panel.
 8. The snap-together plastic panel assembly of claim1 wherein at least one of the panels is embossed with a wood-graintexture.
 9. The snap-together plastic panel assembly of claim 6 whereinthe corrugated panel is shaped and configured to allow multiple ones ofthe corrugated panels to be nested during shipping or storage.
 10. Thesnap-together plastic panel assembly of claim 9 wherein the corrugatedpanel has barbs or catches formed along at least one edge and the shapeand configuration of the panel is adapted to allow multiple ones of thepanel to be nested, as for stacking in shipment and storage, withoutcrushing the barbs or catches.
 11. The snap-together plastic panelassembly of claim 1 wherein at least one of the panels is partiallyfoamed to reduce weight, the foamed panel having outer layers which arenot foamed sandwiching a foamed core.
 12. A self-locking panel assemblyfor mounting between a pair of fence posts or deck posts, the panelassembly comprising: a first elongate rail having an elongate loweropening; a second elongate rail having an elongate upper opening; anelongate fence panel having an upper edge and a lower edge, the upperedge adapted to be inserted into the lower opening of the first elongaterail, and the lower edge adapted to be inserted into the upper openingof the second rail, and wherein catches are formed in at least one ofthe first and second rails and/or in the edges of the fence panel suchthat when the upper and lower edges of the fence panel are inserted intothe openings in the rails the catches hold the fence panel securely inplace in the rails.
 13. The self-locking panel assembly of claim 12wherein the catches comprise barbs.
 14. The self-locking panel assemblyof claim 13 wherein the barbs are formed in the edges of the panel. 15.The self-locking panel assembly of claim 13 wherein the barbs are formedin the rails.
 16. The self-locking panel assembly of claim 12 whereinthe panel is a privacy panel.
 17. The self-locking panel assembly ofclaim 12 wherein the panel is a lattice panel.
 18. The self-lockingpanel assembly of claim 12 further comprising: a third elongated railhaving an elongated lower opening, wherein the first elongated railfurther comprises an upper elongated opening; and a lattice panel havingan upper edge and a lower edge, the upper edge adapted to be insertedinto the lower opening of the third elongated rail and the lower edgeadapted to be inserted into the upper edge of the first elongated rail.19. The self-locking panel assembly of claim 18 further comprising aplurality of catches formed into at least one of the first and thirdrails and/or in the edges of the lattice panel such that when the upperand lower edges of the lattice panel are inserted into the openings inthe rails the catches hold the lattice panel securely in place in therails.
 20. The self-locking panel assembly of claim 16 wherein theprivacy panel is a corrugated panel.
 21. The self-locking panel assemblyof claim 20 wherein the corrugated panel has barb-like catches formedtherein.
 22. The self-locking panel assembly of claim 16 wherein theprivacy panel comprises one or more solid board-like elements.
 23. Asnap-together plastic panel assembly of claim 18 wherein at least one ofthe panels is embossed with a wood-grain texture.
 24. A snap-togetherplastic panel assembly of claim 12 wherein the panel comprises acorrugated panel with barbs or catches formed along at least one edgeand the shape and configuration of the panel is adapted to allowmultiple ones of the panel to be nested, as for stacking in shipment andstorage, without crushing the barbs or catches.
 25. A snap-togetherplastic panel assembly of claim 18 wherein at least one of the panels ispartially foamed to reduce weight, the foamed panel having outer layerswhich are not foamed sandwiching a foamed core.
 26. A plastic panel foruse in a fence between fence posts or in a deck railing between deckposts, the plastic panel comprising: a corrugated plastic panel havingbarbs or catches formed therein along upper and lower edges of thecorrugated plastic panel; and wherein the corrugated plastic panel issized and configured to allow multiple ones of the panel to be stackedin a closely nested arrangement for shipping and/or storage withoutcrushing the barbs or catches formed therein.